Apparatus and method for moving and placing granulate

ABSTRACT

An Improved Apparatus and Method for Moving and Placing Granulate is disclosed. The disclosed device is a portable, self-contained apparatus capable of discharging granulate into hard-to-reach areas, as well as providing assistance in covering vast open areas with granulate in a short time. Furthermore, the device and method described herein permit the application of granulate into areas that are normally inaccessible and would require many hours of human labor, and thereby potentially avoiding damage to the site that might be incurred if employing a prior method and device. Still further, the present invention serves to provide discharge of granulate near or adjacent to retaining walls and underneath concrete flatwork

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] This invention relates generally to the placement of granularmaterials and more specifically, to an Improved Apparatus and Method forMoving and Placing Granulate.

[0003] 2. Description of Related Art

[0004] Sand, gravel and rock are used in a variety of applications forthe construction industry. From aggregate base for concrete slabs, toback fill for retaining walls, granular materials, or granulates, areprobably the most widely used substance, outside of concrete, in theconstruction industry What has been a common problem has been moving thegranulate from place to place when a dump truck and/or cranes andmechanical shovels do not have easy access. Over time, many attemptshave been made at solving this problem. FIG. 1 depicts one attempt. FIG.1 depicts a prior art method for constructing and maintaining a golfcourse. FIG. 1 shows how a patented method known as “Golf-CourseConstruction and Maintenance Methods,” of the Guettler, et al, U.S. Pat.No. 5,147,156. The Guettler method involves the movement of sand orgravel from place to place on a golf course In the example shown, sandin a sand pile 10 is transferred to a conveyor 12, which transports thesand into a pneumatic pumping device 14. The pneumatic pumping device 14receives pneumatic air through a supply hose 16 from a compressor 18that presumably is trailered to the appropriate location. The Guettlermethod includes pressurizing the sand in the pneumatic pumping device14, discharging it through the hose 20, and out the discharge nozzle 22.In this manner, the sand pile 10, or other sand deposit, can be movedfrom place to place, such as into a new sand trap, very quickly andeasily and without the need of wheelbarrows or dump trucks running backand forth across the golf course.

[0005] Although the Guettler system is very effective for a golf course,it is not suitable for a wide variety of construction applications in atraditional construction environment. Since the Guettler method does notinclude the use of a single unitary vehicle, it is necessary to drag thecompressor 18 and the pneumatic pumping device 14 by truck or other towdevice to the location for its use. As such, there is a potential fordamage or loss of components and further the simple additionaldifficulties involved with the on-site erection and dismantling of thevarious components to be used. Furthermore, there is no indication thatthe Guettler unit permits the regulation of pressure. As it will bediscussed later in the present disclosure, there are severalapplications where high discharge pressure of the granulate willprohibit the apparatus's use in certain applications. What is neededtherefore, is a unitary vehicle that can be driven over the road, thatcan further move sand, gravel or rock, or other granulate, and thatfurther permits the regulation of inlet air pressure to very low levelsfor specific applications.

[0006] Another application, namely the construction of concrete flatwork(slabs on grade and the like) typically require a 2- to 6-inch layer ofsand, gravel or other granular material underneath a concrete slab. Inthese applications, a vapor barrier is often required in order toprovide moisture protection. The material of choice for vapor barriersis typically of a size and material that is job-site-specific, andtherefore delivered directly from the vendor to a location adjacent tothe flatwork in progress. Since the vapor barrier and subsequentgranulate installation are the final steps preceding the actual concretepouring, they are not completed until all other mechanical, electricallines and footing reinforcement bars have been installed. As such, heavyequipment cannot be driven over the pad (and lines and bars) because thelines and bars (and vapor barrier) would be disturbed. Because of thisrestriction, the granulate has heretofore been applied manually withwheelbarrows and shovels.

[0007] Furthermore, the process of concrete flatwork usually involvesthe installation of a perimeter forms for the slab (i.e. within whichthe concrete would be poured). These perimeter forms also interfere withthe use of heavy equipment to load the granulate into the pad. What isneeded is a device and method that permits the transfer of granulateinto a concrete flatwork pad without disturbing the mechanical andelectrical lines, the reinforcing bars, the vapor barrier or theperimeter forms.

[0008]FIG. 2 describes another attempt at solving the problem describedabove. FIG. 2 is another prior art method of moving and placing granularmaterials. FIG. 2 is a depiction of the Lightle “Method of Moving andPlacing Granular Materials.” U.S. Pat. No. 5,795,108. The Lightle methodinvolves a truck 24, upon which is mounted a bed 26, within whichgranular material 28 is placed. The system also includes a separate aircompressor 25 for supplying compressed air through the hose 27 to thetruck 24. In operation, the granular material 28 exits the back of thebed 26, via the conveyor 30, where it will drop into the hopper 32. Thehopper 32 then feeds a first pumping device 34 and a second pumpingdevice 36, which are supplied by compressed air or other fluid, similarto the Guettler system. Granulate exiting the first pumping device 34does so via the first hose 38 and then exits via the first nozzle 40. Afurther aspect of the Lightle method includes adding water at the firstwater inlet 42 just as the granulate is leaving the first nozzle 40.Similarly, granulate being pumped from the second pumping device 36 doesso via the second hose 44 and second nozzle 46 whereat water is added atthe second water inlet 48.

[0009] One problem with the Lightle unit is that once the truck bed 26is devoid of granular material 28 (i.e. it's empty), the truck 24 mustdepart the site to get refilled at some industrial location (that hasthe capability of filling a dump truck-sized bed). Since the hopper 32is configured only to receive granulate from the truck bed 26, there isno other way for feeding the first and second pumping devices, 34 and 36respectively. Also, the Lightle device does not include an on-boardcompressed air source (i.e. mounted to the vehicle itself). What isstill needed, therefore, is a fully self-contained unitary vehicle thatworks for sand, gravel and equivalent granulates, that does not need toleave the site at any time to replenish the granulate.

SUMMARY OF THE INVENTION

[0010] In light of the aforementioned problems associated with the priordevices and methods, it is an object of the present invention to providean Improved Apparatus and Method for Moving and Placing Granulate. It isan object that the present invention provide a portable, self-containedapparatus capable of discharging granulate into hard-to-reach areas, aswell as providing assistance in covering vast open areas with granulatein a short time. It is a further object that the device and methodpermit the application of granulate into areas that are normallyinaccessible and would require many hours of human labor, and therebypotentially avoiding damage to the site that might be incurred ifemploying a prior method and device. It is a still further object thatthe present invention serve to provide discharge of granulate near oradjacent to retaining walls and underneath concrete flatwork.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The objects and features of the present invention, which arebelieved to be novel, are set forth with particularity in the appendedclaims. The present invention, both as to its organization and manner ofoperation, together with further objects and advantages, may best beunderstood by reference to the following description, taken inconnection with the accompanying drawings, of which:

[0012]FIG. 1 depicts a prior art method for constructing and maintaininga golf course;

[0013]FIG. 2 is another prior art method of moving and placing granularmaterials;

[0014]FIG. 3 is a perspective view of a preferred self-propelledgranulate application apparatus of the present invention;

[0015]FIG. 4 is a back view of a preferred feeder/hopper means;

[0016]FIG. 5 is a side view of a prior art method for filling conduit;

[0017]FIG. 6 is a block diagram of another preferred embodiment of theapparatus of the present invention; and

[0018]FIG. 7 is a series of side views of the improved method forfilling conduit using the apparatus of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] The following description is provided to enable any personskilled in the art to make and use the invention and sets forth the bestmodes contemplated by the inventors of carrying out their inventionVarious modifications, however will remain readily apparent to thoseskilled in the art since the generic principles of the present inventionhave been defined herein specifically to provide an Improved Apparatusand Method for Moving and Placing Granulate.

[0020] The present invention can best be understood by initialconsideration of FIG. 3. FIG. 3 is a perspective view of a preferredself-propelled granulate application apparatus 50 of the presentinvention. As can be seen, the apparatus 50 comprises a fully functionaltruck 52 having a substantially flat bed 54 upon which is mounted a highcapacity air compressor 56. What is unique, is the fact that rather thanmounting a receptacle for granulate on the bed 54, all that is mountedthere is the air compressor 56, the feeder/hopper means 58, the pumpingdevice 60 and the hose 62. The feeder/hopper means 58 is configured toreceive loads of granulate and then feed the granulate in a consistentmanner into the attached pumping device 60 for pneumatic compressioninto the hose 62. The hose 62 is stored on a hydraulic or air drivenreel which dispenses the hose 62 for quick set-up and retracts it forease of returning to storage on the truck 52. Again, what is unique hereis that the mouth 66 of the feeder/hopper means 58 is configured toreceive loads from a loader tractor or other piece of loading equipment,such that the feeder/hopper means 58 can be supplied with a continuousflow of granulate, essentially until the truck 52 runs out of fuel.which in effect is an indefinite time, since the truck 52 will haveenough fuel to run all day, and at least through one shift of humanlaborers, if not more. It is a simple matter of providing a continuousflow of granulate to the feeder/hopper means 58 via the mouth 66, suchas by a loader tractor, while another technician administers the hose 62and nozzle 64 to apply the granulate in the desired location.Furthermore, the apparatus 50 includes a tow hitch 68 at its rear endfor hitching the aforementioned loader tractor thereto so that theapparatus 50 can be driven on the road virtually anywhere with theloader tractor in tow (on a trailer). Once arriving at the site, theloader tractor (on its trailer) is off-loaded from the unitary vehicle50 and the trailer (not shown) is disconnected therefrom as well.Subsequently, the loader tractor moves granulate (including rock, sand,gravel or other material) from the granulate stockpile 57 and into themouth 66 of the feeder/hopper means 58.

[0021] It should further be appreciated that the single hose model shownhere is simply one embodiment; in other embodiments, the vehicle 50 willinclude an optional second pumping device and hose combination (and eventhird), working from the same hopper supply and air source. This optionprovides increased production for high volume output and/or a back-up ifone of the pumping devices requires maintenance.

[0022] If we now turn to FIG. 4, we can examine another unique aspect ofthe present invention. FIG. 4 is a back view of a preferredfeeder/hopper means 58. FIG. 4 depicts the feeder/hopper means 58, andas can be seen, the mouth 66 spans the entire opening in the chute 70 atthe top of the feeder/hopper means 58. The mouth 66 is configured to below enough to the ground so that the loader tractor can dump a loadtherein. Furthermore, there is a grating 72 to prevent foreign objectsor people from falling into the hopper area 74.

[0023] One distinct problem with previous methods, and in particularwith the transport of rock, has been the providing of a consistentnon-fluctuating flow of gravel from the feed side to the pumping device60. In the present invention, this is accomplished by providing acompactor drive apparatus 76. The compactor drive apparatus 76 isessentially a screw auger which is tilted at an angle, such that thenatural inclination of the rock is to fall to the lower section of thecompactor drive apparatus 76, after which the internal mechanisms forcethe rock up in direction 78 until they finally reach the compactordischarge point 80, where the rock falls into the pumping device 60 fordischarge through the hose 62 and nozzle 64. In this way then, anyclumping or air space is removed from the granulate, including rock,gravel or sand, while the granulate is forced in direction 78 by thecompactor drive apparatus 76. As a result, the pumping device 60experiences a consistent non-fluctuating flow of granulate for pumpingthrough the hose 62.

[0024] Another substantial benefit gained through use of the device andmethod of the present invention involves the backfilling of retainingwalls, in areas inaccessible by tractors or wheelbarrows.

[0025] If we now turn to FIG. 5 we can discuss yet another advantage ofthe present invention. FIG. 5 depicts conventional means for filling aconduit 82. As can be seen in this simulation, the conduit 82 is a largediameter pipe, having a first opening 84 and a second opening 86 oneither side of a thoroughfare 88, such as a road or freeway. It isthrough these conduits 82 that many services such as cables, or smallersupply pipes pass under the thoroughfare 88. For structural reasons,however, the conduit 82 cannot remain open, but must be filled with somesort of non-compacting material. This is typically accomplished byfilling it with sand. As can be seen in FIG. 5B, the conventional methodis to first install a cement plug 90, for example, to cover the secondopening 86 in the conduit 82. A series of brackets 83 are then welded orotherwise attached in place inside of the conduit 82 in order torestrain the application pipe of a conventional sand blasting rig. Whathappens next is that the sandblasting rig is is activated and sandbegins to fill in the direction 92 through the application pipe placedin the first opening 84. The problem is that as the sand fills in thedirection 92, the pipe must be slid back and removed section by section.The application pipe is pulled back, the rig is shut down, a section ofpipe is cut out and the supply hose is reconnected. This is done severaltimes in the course of filling the conduit 82 until sand is filled asclose as possible to the first opening 84.

[0026] If we now turn to FIG. 6, we can discuss how a novel aspect ofthe present invention provides a substantial benefit in the filling ofconduit and other piping with sand. FIG. 6 is a block diagram of thepertinent portions of the apparatus of the present invention. As can beseen, the compressor 56 feeds the pumping device 60 with compressed air,while granulate material 28 is fed into the feeder/hopper means 58 anddischarged from the pumping device 60 through hose 62 and out throughnozzle 64. What is unique is that the present invention includes aregulating means 94 for regulating the air pressure between thecompressor 56 and the pumping device 60. The regulating means 94provides the ability to regulate the compressor pressure 56 dischargeall the way down to approximately 15 psi while still maintaining highvolume of air. It should be appreciated that depending upon the type ofgranulate being pumped, the regulating means 94 might be adjusted toincrease or decrease the discharge pressure of the compressor 56.

[0027] If we now turn to FIG. 7, we can examine how the aforementionedregulating means 94 can provide an improved process for filling conduit82. FIG. 7 is a series of side views of the improved method for fillingconduit using the apparatus of the present invention. As can be seen inFIG. 7A, step 1 includes installing a plug 96 to enclose the secondopening 86. This new plug 96 includes a vent 98. Step 2 involvesinstalling a second plug 100 to close the first opening 84. The secondplug 100 includes and inlet tap 102. The inlet tap 102 includes themeans for attaching 104 the hose 62 thereto. Once the first plug 96 andthe second plug 100 are installed, and the hose 62 is attached to theattaching means 104, FIG. 7B depicts how the conduit is filled. Thedischarge pressure is reduced via the regulating means 94 toapproximately 15 psig. Because the pressure is so low, essentially, airflows through the conduit 82 and out through the vent 98 whiledepositing sand in the bottom of the conduit 82. As a result, sand fillsthe conduit 82 in the direction 106 (bottom-to-top rather thanend-to-end). When the conduit 82 is filled with sand, it is readilyapparent, because sand will begin to be forced out through the vent 98,after which the vent 98 is simply capped off and thereafter the inletLap 102 is also removed and capped off. In practice then, the improvedsystem can fill a conduit 82 in a fraction of the time of thepreviously-described process, since no stopping and cutting is necessaryand the labor and materials to install the pipe and pipe hangers iseliminated.

[0028] In examining each of the aforementioned embodiments of thepresent invention, it should be understood that the term “unitaryvehicle” as used in connection with the present invention, refers toboth a self-propelled vehicle as well as a towed vehicle (such as atrailer).

[0029] Those skilled in the art will appreciate that various adaptationsand modifications of the just-described preferred embodiment can beconfigured without departing from the scope and spirit of the invention.Therefore, it is to be understood that, within the scope of the appendedclaims, the invention may be practiced other than as specificallydescribed herein.

What is claimed is:
 1. Self-propelled granulate application apparatus,comprising: a bed; a pumping means for pumping granulates, said pumpingmeans including a compressor device; and feeder/hopper means extendingfrom said bed for accepting granulates and feeding same to said pumpingdevice.
 2. The apparatus of claim 1, wherein said feeder/hopper means isdefined by a mouth, said mouth configured to be reached by small loadingequipment,
 3. The apparatus of claim 2, wherein said feeder/hopper meansis further defined by a hopper area adjacent to said mouth.
 4. Theapparatus of claim 3, further defined by compactor drive means adjacentto said hopper, for compacting said granulate and feeding it in aconsistent stream to said pumping device.
 5. The apparatus of claim 4,wherein said compactor drive means comprises: an angled housing defininga longitudinal top opening and a discharge point; and a drive screwcooperatively located in said housing whereby granulate fed through saidtop opening onto said drive screw will be urged out through saiddischarge point when said drive screw is rotated.
 6. The apparatus ofclaim 5, wherein said pumping means is supplyable with compressed fluidfrom said compressor via a supply pipe, said supply pipe further definedby a regulating means for regulating the pressure of said compressedfluid.
 7. A method for filling conduit piping with sand and other finegranulates, said conduit having at least a first and second end, eachsaid end respectively defined by a first and second opening, comprisingthe steps of: placing first and second plugs in said first and secondopenings to define an enclosure inside said conduit, said first plugfurther defined by an inlet tap; and transferring said fine granulatethrough said inlet tap in a fluid stream until said enclosure issubstantially full.
 8. The method of claim 7, wherein said placing stepfurther comprises placing said second plug in said second opening,wherein said second plug is defined by a vent.
 9. The method of claim 8,wherein said transferring step is ceased when said granulate begins toexit from said vent.
 10. Unitary granulate pumping apparatus,comprising: a bed; pumping means for pumping granulates through a hosevia gas pressure, said gas pressure provided by a compressor devicelocated on said apparatus; and feeder/hopper means extending from saidbed for accepting granulates and feeding same to said pumping device.11. The apparatus of claim 10, wherein said feeder/hopper means isfurther defined by a hopper area.
 12. The apparatus of claim 11, whereinsaid feeder/hopper means is defined by a mouth opening into said hopperarea, said mouth configured to be reachable by a loader tractor.
 13. Theapparatus of claim 12, further defined by compactor drive means adjacentto said hopper, for feeding said granulate in a consistent stream tosaid pumping device.
 14. The apparatus of claim 13, wherein saidcompactor drive means comprises: an angled housing defining alongitudinal top opening, a drive chamber and a discharge point; and adrive screw cooperatively located in said drive chamber wherebygranulate fed through said top opening onto said drive screw will beurged out through said discharge point when said drive screw is rotated.15. The apparatus of claim 14, wherein said pumping means is supplyablewith compressed gas from said compressor via a supply pipe, said supplypipe further defined by a regulating means for regulating the pressureof said compressed gas.
 16. A method for back-filling granulate toremote locations, comprising the steps of: pumping said granulate tosaid remote locations, said pumping accomplished with a unitaryvehicle-mounted granulate placement apparatus.
 17. The method of claim16, wherein said pumping step begins after said granulate is firstloaded into said apparatus via a loader tractor.
 18. The method of claim17, wherein said loading step comprises loading said granulate into amouth of a feeder/hopper apparatus.
 19. The method of claim 18, whereinsaid pumping step begins after said granulate falls from said mouth intoa hopper area located in said feeder/hopper apparatus.
 20. The method ofclaim 19, wherein said pumping step begins after said granulate istransported by a compactor drive means from said hopper area to apumping means for pumping said granulate to a remote location.
 21. Amethod for placing granulate in backfill areas of retaining walls,comprising the steps of: pumping said granulate to said backfill area,said pumping accomplished with a unitary vehicle-mounted granulateplacement apparatus.
 22. The method of claim 21 wherein said pumpingstep begins after said granulate is first loaded into said apparatus viaa loader tractor.
 23. The method of claim 22, wherein said loading stepcomprises loading said granulate into a mouth of a feeder/hopperapparatus.
 24. The method of claim 23, wherein said pumping step beginsafter said granulate falls from said mouth into a hopper area located insaid feeder/hopper apparatus.
 25. The method of claim 24, wherein saidpumping step begins after said granulate is transported by a compactordrive means from said hopper area to a pumping means for pumping saidgranulate to a remote location.
 26. A method for placing granulate inbeds for concrete flatwork, comprising the steps of: pumping saidgranulate to said beds, said pumping accomplished with a unitaryvehicle-mounted granulate placement apparatus.
 27. The method of claim26, wherein said pumping step begins after said granulate is firstloaded into said apparatus via a loader tractor.
 28. The method of claim27, wherein said loading step comprises loading said granulate into amouth of a feeder/hopper apparatus.
 29. The method of claim 28, whereinsaid pumping step begins after said granulate falls from said mouth intoa hopper area located in said feeder/hopper apparatus.
 30. The method ofclaim 29, wherein said pumping step begins after said granulate istransported by a compactor drive means from said hopper area to apumping means for pumping said granulate to a remote location.